Finger Joint Panel

ABSTRACT

In accordance with an example embodiment, there is disclosed herein, a panel that comprises a plurality of ornamental sections having a predefined shape, the plurality of ornamental sections are arranged in rows that form a staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel. A plurality of interior grooves are located between the ornamental sections, the interior grooves having a first width. A plurality of partial grooves having a second width are located along the at least one edge of the panel. Ornamental sections at an edge of a protruding row comprise convex curves having a first radius at their edges. Ornamental sections at the edge of recessed rows comprise concave curves having a second radius at their edges.

TECHNICAL FIELD

The present disclosure relates generally to wall panels.

BACKGROUND

Wall panels provide durable, water-resistant, attractive, and affordable interior walls for commercial and residential spaces. Typically, wall panels are sized at 4′×8′ and 4′×10′. When the wall panels are installed side by side, an unsightly seam is formed between the panels. Attempts to reduce the visibility of the seam include butt-jointing the seams together applying additional trim pieces to the seam, and/or space the seams at very specific intervals and apply a bead of color matching sealant, very precisely along the seam. These techniques require additional time and/or expertise to install the panels. and still result in an unsightly seam along the entire length of the panel.

SUMMARY OF EXAMPLE EMBODIMENTS

The following presents a simplified overview of the example embodiments in order to provide a basic understanding of some aspects of the example embodiments. This overview is not an extensive overview of the example embodiments. It is intended to neither identify key or critical elements of the example embodiments nor delineate the scope of the appended claims. Its sole purpose is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with an example embodiment, there is disclosed herein, a panel that comprises a plurality of ornamental sections having a predefined shape, the plurality of ornamental sections are arranged in rows that form a staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel. A plurality of interior grooves are located between the ornamental sections, the interior grooves having a first width. A plurality of partial grooves having a second width are located along the at least one edge of the panel. Ornamental sections at an edge of a protruding row comprise convex curves having a first radius at their edges. Ornamental sections at the edge of recessed rows comprise concave curves having a second radius at their edges.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification illustrate the example embodiments.

FIG. 1 illustrates an example of a panel in accordance with an example embodiment.

FIG. 2 illustrates an example of a finger joint formed when two panels configured as illustrated in FIG. 1 are installed adjacent to each other.

FIG. 3 is an enlarged view of the area bounded by A in FIG. 2.

FIG. 4 is a cross sectional view along B-B in FIG. 3.

FIG. 5 illustrates an example of a circular groove.

FIG. 6 illustrates an example of a V-shaped groove.

FIG. 7 illustrates an example of a rectangular groove.

FIG. 8 is an exploded view of a plurality of panels having rectangular ornamental sections.

FIG. 9 is an exploded view of a plurality of panels having square ornamental sections.

FIG. 10 is an exploded view of a plurality of panels having hexagonal ornamental sections.

FIG. 11 is an exploded view of a plurality of panels having octagonal ornamental sections.

FIG. 12 is an exploded view of a plurality of panels having rectangular ornamental sections tilted at 45 degree angles.

FIG. 13 is an exploded view of a plurality of panels having finger joints formed by two rectangular ornamental sections tilted at 45 degree angles.

FIG. 14 illustrates an example methodology for manufacturing a panel described herein.

DESCRIPTION OF EXAMPLE EMBODIMENTS

This description provides examples not intended to limit the scope of the appended claims. The figures generally indicate the features of the examples, where it is understood and appreciated that like reference numerals are used to refer to like elements. Reference in the specification to “one embodiment” or “an embodiment” or “an example embodiment” means that a particular feature, structure, or characteristic described is included in at least one embodiment described herein and does not imply that the feature, structure, or characteristic is present in all embodiments described herein.

Described in an example embodiment herein are a panel that employ a finger joint for joining adjacent panels. The panels are formed using new and original CNC cutting techniques along with a unique, exclusive design. In an example embodiment, the finger joint panel works like a puzzle piece. The panel is cut in a way that does not leave any partial tiles, resulting in only full tiles on the finished product. Additionally, as will be described herein, partial grooves are cut into the finger jointed edges. These partial grooves give the appearance of uninterrupted grout joints when installed. The finger joint panels install directly into each other, creating a joint that does not require added trim, added color-specified sealant, or additional time or expertise to install. This can reduce up-front accessory costs, installation costs, and results in a wall with seams that are almost invisible to the naked eye.

FIG. 1 illustrates an example of a panel 10 in accordance with an example embodiment. The panel 10 comprises a plurality of ornamental sections 12 having a predefined shape, the plurality of ornamental sections 12 are arranged in rows 14, 16 that form a staggered arrangement with protruding rows 14 and recessed rows 16 between the protruding rows along at least one edge 18 of the panel. Between the ornamental sections are a plurality of interior grooves 20. The interior grooves 20 having a first width “W.” A plurality of partial grooves 22 having a second width are located along the at least one edge 18 of the panel 10. The ornamental sections 12 at an edge 18 of a protruding row 14 (or fingers) comprises convex curves 24 having a first radius at edges of the ornamental section. The ornamental section 12 at the edge of a recessed rows 16 comprise concave curves 26 having a second radius.

In an example embodiment, the width of the grooves along the edge (second width) is one-half the width of the interior grooves (first width). When installed next to adjacent panel that also has groove along the edge that is one-half the width of the interior grooves, this will result in a groove between the panels having the same width as the interior grooves.

In the example illustrated in FIG. 1 the interior grooves 20 and partial grooves 22 are circular. However, those skilled in the art can readily appreciate the grooves 20, 22 can be any suitable shape. Examples of suitable shapes for the interior grooves 20 and partial grooves 22 include, but are not limited to, circular, V shaped, rectangular, elliptical, or square.

In an example embodiment, the radius of convex curves 24 (the first radius or outside radius) of ornamental sections 12 at the edge 18 of protruding rows 14 are the same as the radius of the concave curves 26 (the second radius or inside radius) of the ornamental sections 12 at the edge 18 of recessed rows 26. However, as those skilled in the art can readily appreciate that it may be difficult to achieve exactly equal radiuses for the first and second radiuses, in an example embodiment, the length of the second radius is within a specified tolerance (e.g., 15% or machining tolerances) of the length of the first radius.

The ornamental sections 12 of the panel 10 illustrated in FIG. 1 rectangular. However, those skilled in the art should readily appreciate that any suitable shape is acceptable. Examples of suitable shapes include, but are not limited to, square, cubical, hexagonal, or rectangles at a 45 degree angle from the edge 18.

The panel 10 can be made of any suitable material. Examples of suitable materials the panel can be made from include, but are not limited to, Fiberglass Reinforced Plastic (FRP), high density Fiberboard (HDF), Medium-density Fiberboard (MDF), or Plastic Board, or laminated composite board.

FIG. 2 illustrates an example of a finger joint 28 formed when two panels 10 a, 10 b configured as illustrated in FIG. 1 are installed adjacent to each other. The partial grooves 22 form a groove of the same width as the interior grooves 20. The convex curves 24 of the protruding ornamental sections 12 mesh with the concave curves 26 of ornamental sections 12 of the adjacent panel. This can give the appearance of uninterrupted grout joints when installed. The finger joint panels 10 a, 10 b install directly into each other, creating a finger joint 28 that does not require added trim, added color-specified sealant, or additional time or expertise to install. This can reduce up-front accessory costs, installation costs, and results in a wall with seams that are almost invisible to the naked eye.

FIG. 3 is an enlarged view of the area bounded by A in FIG. 2. FIG. 3 further illustrates that when partial grooves 22 a, 22 b corresponding to panels 10 a, 10 b respectively abut, the width of the combined partial grooves 22 a, 22 b is equal to the width of interior grooves 20 a, 20 b corresponding to panels 10 a, 10 b, respectively. FIG. 3. also further illustrates how convex curves 24 of ornamental sections 12 of protruding rows (or fingers) merge with concave curves 26 when panels 10 a, 10 b abut.

FIG. 4 is a cross sectional view along B-B in FIG. 3. This view illustrates an example of a portion of the finger joint 28 where partial grooves 22 a, 22 b of panels 10 a, 10 b respectively This view illustrates an example of a portion of the finger joint 28 where partial grooves 22 a, 22 b abut to form a groove

FIG. 5 illustrates an example of a circular groove. This view illustrates an example of a portion of the finger joint 28 where partial grooves 22 a, 22 b abut to form a circular groove.

FIG. 6 illustrates an example of a V-shaped groove. This view illustrates an example of a portion of the finger joint 28 where partial grooves 22 a, 22 b abut to form a V-shaped groove.

FIG. 7 illustrates an example of a rectangular groove. This view illustrates an example of a portion of the finger joint 28 where partial grooves 22 a, 22 b abut to form a rectangular groove.

FIG. 8 is an exploded view of a plurality of panels 10 c, 10 d having rectangular ornamental sections. The rows of the panels 10 c, 10 d are staggered so that when panels 10 c, 10 d abut they form a finger joint as described herein.

FIG. 9 is an exploded view of a plurality of panels 10 e, 10 f having square ornamental sections. The rows of the panels 10 e, 10 f are staggered so that when panels 10 e, 10 f abut they form a finger joint as described herein.

FIG. 10 is an exploded view of a plurality of panels 10 g, 10 h having hexagonal ornamental sections. The rows of the panels 10 g, 10 h are staggered so that when panels 10 g, 10 h abut they form a finger joint as described herein.

FIG. 11 is an exploded view of a plurality of panels 10 j, 10 k having octagonal ornamental sections. The rows of the panels 10 j, 10 k are staggered so that when panels 10 j, 10 k abut they form a finger joint as described herein.

FIG. 12 is an exploded view of a plurality of panels 10 m, 10 n having rectangular ornamental sections tilted at 45 degree angles from the top edge 30 and/or the bottom edge 32. In this example embodiment, when panels 10 m, 10 n abut, the resulting finger joint is a zig zag pattern. The convex curve 24 of the protruding ornamental section (or finger) abuts a concave curve 26 formed at a point where two ornamental sections abut.

FIG. 13 is an exploded view of a plurality of panels 10 p, 10 q having finger joints formed by two rectangular ornamental sections that are tilted at 45 degree angles from the top edge 30 and/or the bottom edge 32. In this example embodiment, when panels 10 p, 10 q abut, the resulting finger joint is a zig zag pattern. The convex curve 24 of the protruding ornamental section (or finger) abuts a concave curve 26 formed at a point where two ornamental sections abut.

In view of the foregoing structural and functional features described above, a methodology 1400 in accordance with an example embodiment will be better appreciated with reference to FIG. 14. While, for purposes of simplicity of explanation, the methodology 1400 of FIG. 14 is shown and described as executing serially, it is to be understood and appreciated that the example embodiment is not limited by the illustrated order, as some actions could occur in different orders and/or concurrently with other actions from that shown and described herein. Moreover, not all illustrated features may be required to implement a methodology in accordance with an example embodiment.

At 1402, the panel is formed. The panel can be formed using any suitable technique which can depend on the type of material being employed to make the panel. of suitable materials the panel can be made from include, but are not limited to, Fiberglass Reinforced Plastic (FRP), high density Fiberboard (HDF), Medium-density Fiberboard (MDF), Plastic Board, or laminated composite construction. The rows are formed with staggered rows and the shape of the edges can depend on the desired ornamental sections. For example, as illustrated in FIGS. 1-13 the panels can have rectangular, square, hexagonal, octagonal, or tilted rectangle ornamental sections, therefore, the edges of the panel would comport with the type of shape ornamental sections.

At 1404, the interior grooves are machined into the panel. For example, the interior grooves can be circular, elliptical, V-shaped, or rectangular. CNC machining can be employed for cutting the grooves into the panel.

At 1406, the partial grooves are machined along at least one edge of the panel. In an example embodiment, the partial grooves correspond o the interior grooves of the panel. For example, the partial grooves can be one-half of a circular, elliptical, V-shaped, or rectangular groove. CNC machining can be employed for cutting the partial grooves into the panel.

At 1408, the curves are machined into the outer (protruding or finger) corners of the panel. The curves for the outer panel are convex and have a first radius. CNC machining can be employed for machining he outer corners,

At 1410, the curves are machined into the inner (recessed) corners of the panel. The curves for the inner panel are concave and have a second radius. CNC machining can be employed for machining he outer corners. In an example embodiment, the radius of the inner corner and the radius of the outer corner are equal or within a specified tolerance (e.g., 15%) of each other.

Described above are example embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies, but one of ordinary skill in the art will recognize that many further combinations and permutations of the example embodiments are possible. Accordingly, this application is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. 

1. A panel, comprising: a plurality of ornamental sections having a predefined shape, the plurality of ornamental sections are arranged in rows that form a staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel; a plurality of interior grooves that are located between the ornamental sections, the interior grooves having a first width; and a plurality of partial grooves having a second width that are located along the at least one edge of the panel; wherein an ornamental section at an edge of a protruding row comprises convex curves having a first radius at edges of the ornamental section; and wherein an ornamental section at an edge of a recessed row comprises concave curves having a second radius at edges of ornamental sections of recessed rows.
 2. The panel set forth in claim 1, wherein the second width is one-half the first width.
 3. The panel set forth in claim 1, wherein the first radius is equal to the second radius.
 4. The panel set forth in claim 1, wherein the second radius is within a specified tolerance of the first radius.
 5. The panel set forth in claim 1, wherein the ornamental sections are rectangular.
 6. The panel set forth in claim 1, wherein the ornamental sections are square.
 7. The panel set forth in claim 1, wherein the ornamental sections are cubical.
 8. The panel set forth in claim 1, wherein the ornamental sections are hexagonal.
 9. The panel set forth in claim 1, wherein the ornamental sections are rectangular and at a 45 degree angle.
 10. The panel set forth in claim 1, wherein the interior grooves and partial grooves are circular.
 11. The panel set forth in claim 1, wherein the interior grooves and partial grooves are V shaped.
 12. The panel set forth in claim 1, wherein the interior grooves and partial grooves are rectangular.
 13. The panel set forth in claim 1, wherein the interior grooves and partial grooves are elliptical.
 14. The panel set forth in claim 1, wherein the interior grooves and partial grooves are square.
 15. The panel set forth in claim 1, wherein the panel is made of Fiberglass Reinforced Plastic.
 16. The panel set forth in claim 1, wherein the panel is made of High-Density Fireboard.
 17. The panel set forth in claim 1, wherein the panel is made of Medium-Density Fiberboard.
 18. The panel set forth in claim 1, wherein the panel is made of Plastic Board.
 19. The panel set forth in claim 1, wherein the panel is made of a laminated composite construction.
 20. A method, comprising: forming a panel with staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel; machining grooves into the panel forming ornamental shapers therein; machining partial grooves around the at least one edge of the panel; machining convex curves having a first radius on ornamental sections at the at least one edge of protruding rows; and machining concave curves having a second radius on ornamental sections at the at least one edge of recessed rows.
 21. The method set forth in claim 20, wherein the first radius is equal to the second radius. 